Method of forming laminated stepped gears



Fan, 15 1924.

J. F. KELLER METHOD OF FORMING LAMINATED STEPPED GEARS Filed July 22 1920 4 Sheets-Sheet 1 I M a Fan. 15 1924., r

J, F. KELLER METHOD OF FORMIN G LAMINATED STEPPED GEARS F i led July 22 1920 4 Sheets-Shqet 2 i 1 M MWM N 1 m m R MWNN 1,481,212 J. F. KELLER Filed July 22 1920 4 Shepos-Sheet 3 Jnuemfoz 2 I I: I

0% .w M v e Jan. 15 1924.

METHOD OF FORMING LAMINATED STEPPED GEARS Jan. 15, 1924. 1,481,212

J. F. KELLER METHOD OF FORMING LAMINATED STEPPE D GEARS Filed July 22 1920 4 Sheets-Sheet 4 '5 W /wmron Patented Jan. 15, 1924.

UNITED STATES PATENT, OFFICE.

JOSEPH F.' KELLER, OF NEW YORK, N. Y., ASSIGNOE TO KELLER MECHANICAL EN- GINEERING CORPORATION, OF BROOKLYN, NEW YORK, .A CORPORATION OF NEW YORK.

METHOD OF FORMING LAMINATED STEPPED GEARS.

Application filed July 22, 1920. Serial No. 888,164.

To all whom it may concgm:

Be it known that I, JOSEPH F. KELLER, a citizen of the United States, and resident of New York, county and State of New York, have invented certain new and useful Improvements in Method of Forming Laminated Stepped Gears of which the following is a specification.

My invention relates more particularly to no the production of stepped gears of thin sheet material, riveted or otherwise secured together to form a solid gear.

It is known that helical gears and stepped gears have been used for rendering intermeshing gears, less noisy, but because of the lateral thrust inhelical gears, stepped gears are preferable. The principal difiiculty in obtaining satisfactory stepped gears, heretofore, has in part due to the difiiculty in uniformly stepping the successive gears by forming the aligning holes uniformly and progressively so as to produce such gears cheaply enough to. insure the 'wide use this type of geardeserve-s.

In order to overcome these difliculties and produce a satisfactor stepped gear, I have devised an improv method of forming the stepped gears of laminae, punched from sheet material, the punches and dies being so arranged that the aligning holes can be readily and quickly advanced uniformly and accurately, for successive laminae, thus mak-- ing it possible to produce cheaply a satisfactory laminated stepped gear.

One advantage of the laminated stepped gear is that more steps can be made for a given Width of face and thus give a more uniform drive and more effectively prevent rattle or noise in the gears during operation.

Another object of my improved laminated stepped gears is to make the stepped gears of alternate laminae of steel or other suitable metal and a non-metallic material, such as fiber, rawhide, bakelite, treated fabric or material of a similar character. In this manner, it will be understood that gears can be made which in operation are practically noiseless.

Another object of m improved invention is to produce stepped aminated bevel gears by punching the lamina gear blanks in the flat and forming them into cup-shaped laminae which, when nested, are adapted to form the required bevel gear, the aligning I have overcome t holes in the successive laminae being advanced relatively to the teeth so that "when assembled and secured together, the bevel teeth are in stepped relation. It will be understood that the stepped bevel gears may be made of alternate laminae of metal and non-metallic material when so desired.

The special unches and dies and forming dies, toget er with examples of my improved laminated gears are more particularly shown in the accompanyi drawings, in which Fig. 1 is a plan view 2% the threestep punch for unching the lamina from sheet material; Fig. 2 is a vertical section through the centers of the punches as shown in Fig. 1; F ig.'3 is a vertical section of the die taken through the center of the dies as shown in Fig. 4;; Fig. 4 is a plan view of the dies mating with the punches of Fig. 1; Fig. 5 is a vertical transverse section on the lines 5-5 of Fig. 2 showing the adjustable punch for the aligning holes; Fi 6 is a vertical transverse section 'on the line 6-6 of Fig. 3 showing the adjustable diesmating with the aligning hole punches; Figs. 8, 9, 10, 11 and 12 represent the keys used successively for adjusting the osition of the aligning hole die shown in ig. 4; Fig. 13 represents a side elevation partially broken away of my improved laminated stepped gear; Fig. 14 represents a face view of the stepped gear of Fig. 13 with a portion in section through one of the aligning pins. Fig. 15 shows my improved laminated stepped bevel gears two forms being shown in mesh; Fig. 16 is a fragment of one of the bevel gears of Fig. 15; Fig. 17 is a sectional view illustratin the stepped die for shaping the lamina for a bevel gear, and Fig. 18 is a die for finishing the teeth of the lamina for a bevel gear.

Punched gears are well-known both plain and laminated but stepped gears of this character have to my knowledge not. been marketed because of the difliculty in properly and uniformily ste ping the successive gears. his objection by devising a three-step punch and die, in the first ste of which the aligning holes are punched and the punch and dies for this purpose are readily and accurately adjustable, to the different positions required, to give uniform stepping to the successive laminae.

-Referring to the drawings, and particularly to Figs. 1 and 2, it will be seen that the three-step unch members are mounted on the usual b ock 1, the punches for the three-steps being equally spaced apart. The strip of metal is moved under the punch block from right to left 1n the usual manner, so that the center hole and the aligning holes are first punched and then the teeth are punched in two operations. By referring to Figs. 1 and 2, it Wlll be seen that the center punch 2 is secured to a counter-bored, cup-shaped block 3, which in turn is secured to the base block 1 by suitable s crews 3 The punches for the aligning holes are indicated at 5 and these are mounted in a disc or block 6 adapted to fit snugly in the counter-bore of the block 3, the aligning hole punches 5 being preferably 3 in number and equally spaced about the center punch 2, although obviously the arrangement and number of al gning holes may be varied. An annular ring 7 is adapted to be secured by screws 8 to the annular flange of the block 3 and overlap the. block or disc 6 so as to hold the latter firmly in place within the socket or center-bore of the block 3.

In order to provide for adjusting the aligning hole punches 5, angularly, with respect to the successive punches for punch-- mg the gear teeth, the disc- 6 is preferably rotatably mounted in the block 3 and is held in adjusted position by a key 8, (see Figs. 1 and 7 adapted to lit snugly in ke slots 9 and 10 formed respectively in the ange of the block 3 and in the peripheral edge of the disc '6. It will be seen from the drawings that the successive key slots 9 and 10 are advanced in the disc 6 so that when the key slots are brought into alignment the disc will be advanced successively of the space or distance between adjacent gear teeth of the gear the punch is adapted to produce.

At the first operation of the punch press, the strip of sheet metal will be punched to form the aligning holes by the punches 5 and the center hole by the punch 2, the strip of metal will then be advanced tobring the punched center-hole in alignment with the centering stud 11 of the first punch for the gear teeth. This comprises a block 12, in which the centering stud 11 is mounted, the block 12 being secured to .the face plate or block 1 by suitable screws 13 as indicated in Fig. 2 of the drawings. 'Suitably spaced about the center pin 11 and near the periphery of the block 12 are a plurality of punches 14 shaped to punch one half of the teeth of the gear, these punches being secured in sockets in the block 12 by screws 15.

When this punching step is complete, the metal stripis again advanced to bring the punched center-hole in alignment with the centering stud 16 of the second punch for desired by forcing it through a finishing die in the usual or any preferred manner.

The punches just described as mounted on the block 1 are adapted to cooperate with the dies or female members mounted upon the block 21 as indicated in Figs. 2 and 4 of the drawings. The block 21 is counterbored in proper position opposite the re-- spcctive punches on the block 1 to receive the mating female members. Opposite the center punch 2 and aligning hole punches 5, disc -22 is inserted in one of the counterbores, the disc 22 being of hardened steel and properly bored out at 23 and 24:, to form the female dies for the punches 2 and 5, respectively. The disc 22 as will be seen more particularly in Fig. 4 of the drawings, is provided with a peripheral notch 25, cooperating with a key 26, accurately ground to hold and position the die discs 22 in proper adjusted position, to cooperate with the punches 5, hereinbefore described as the punches for punching the aligning holes in the gear laminae. It has previousl been explained that the disc 6, together wit the punches 5 is adapted to be shifted angularly with respect to the gear teeth so as to punch the aligning holes of the successive laminae, advanced of the distance between adjacent teeth. The disc 22 of the mating die, in order tocooperate with the punches 5, must be similarly rotated in the plate 21. This may be done by keys and notches such as previously described in connection with the disc 6, carrying the punches 5 and shown in Fig. 7 of the drawings, or I may provide a wider key way in the block 21 to accommodate a key 'with a wider base 27, so that a plurality of keys may be inserted in succession in the key-way of the block 21, the successive keys 26 being located with respect to the base 27, in uniformly advanced positions, thereby permitting the disc 22 to be rotated and locked in proper position to receive the punches 5 for punching the aligning holes in the successive laminae, making up the stepped gear. The five different keys are represented in Figs. 8 to 12 inclusive, the key shown in Fig. 12 corresponding to the one shown in Fig. 4 of the drawings. The width of the base 27 of all ofthe keys being the same, it will readily be understood that the keys may be readily removed and replaced to lock the disc 22 in the predetermined position required to cooperate with the setting of the disc 6, carrying the punches 5. i a

The plate 21 also carries the dies 28 and 29 which are the female members cooperating with the punches l4 and 19i 'respec' die discs 28 and 29 is provided with annularly disposed die openings 31 and 32 located to receive the respective punches 14 and 19, the arrangement being such that the dies and punches for the second punching operation merely punch holes in the plate to represent one half of the teeth and the last punch cooperating with the disc 29 finishes the operation and completes the punching of the gear lamina. The respective centering studs 11 and 16 are adapted to cooperate with and pass through holes 33 and 34 respectively in the discs 28 and 29.

After the gear laminae have been punched:

in the manner described, they may be passed through a finishin die to more accurately shape the teeth if it is found desirable and then the successively punched laminae maybe assembled as indicated in Figs. 13 and 14 of the drawings, to form a stepped spur gear. Obviously, the laminae 35 ot the stepped gear ma be all made of the same material but pre erably, the outside laminae 35 are of steel or other suitable sheet metal, and alternate with laminae 36 of other material, preferably, non-metallic, such as fiber, bakelite, raw-hide or other material found suitable for the purpose. Any num-' ber of laminae may be employed to make up a gear but in the form shown, I prefer to use 5 steps between centers of adjacent teeth, even though the gear represented con 'tains more than 5 laminae. The stepping of the gears is illustrated in Fig. 13 of the drawings in the broken away section as well as in the face view of Fig. 14. The successive laminae are aligned by the aligning holes 37, and secured together in fixed relations by the pins 38 which may be riveted at the ends to firmly hold the laminae together. Obviously, stepped laminated spur gears of the forms indicated may be made of various diameters, according to the requirements, the corresponding inter-meshing gears being stepped in the same manner and a corresponding amount.

My improved method of making stepped gears is particularly important in connection with the production of stepped bevel gears. To roduce laminated stepped bevel gears the aminae are preferably punched from flat sheet stock in the manner previously described and then (39 in Figs. 17

and 18) bent up or formed in a press substantially as indicated in Fig. 17 of the drawings, the discs being thereby formed cup-shaped with the teeth on the edge of the conically disposed flange. According to the description and drawings thus far re ferred to. The bevel gear lamina 39 is indicated in Fig. 17 of the drawings, as bein formed cup-shaped between the die mem' rs 40 and 41, which may be constructed in the usual manner and provided with spring pressed ejecting plungers 42 and 43 a centering plug or stud 44 being mounted on the block 41 and adapted to project throu h the center hole of the gear lamina 39 an enter the hole 45, in the die block 41.

After shaping the successive laminae for the bevel gears by means of the forming die in Fig. 17, it is desirable to properly shape the teeth and for this purpose I preferably employ dies like that shown in Fig. 18 o 'the drawings. The gear laminae 39 are taken from the forming die of Fig. 17 and positioned by pins 46 in the lower die block 47 of the finishing die shown in Fig. 18 of the drawings. The upper block 48 is provided with ejecting lungers 49 and is surrounded by an annu ar die member 50 provided with properly shaped teeth at 51, adapted to form and shape the teeth of the lamina 39 when the latter is pressed between the blocks 47- and 48, in the forming die shown in Fig. 18 of the drawings.

When the bevel gear laminae have been properl formed into cup-shape, they are prefera ly secured together by suitable pins or rivets 52 and 53, as shown in Fig. 15 of the drawings, in one form of bevel gear shown in Fig. 15, it will be noted that I have shown five laminae representing the but only three of the laminae are full-cupshaped, two laminae bein represented by conical rings 54 and 55 w ich are secured to the other lamina by the rivets 53 and alternate therewith in any suitable manner. In the larger beveled gear of Fig. 15, the rivets 53 preferably pass through the rings 5455 and the flanges of cup-shaped laminae, although, obviously, thespecific meth od of securing the level gear laminae together may be varied.

The larger bevel gear of Fig. 15 is preferably mounted on a flanged hub 56 and secured thereto by rivets 52 extending through the lamina and the flange of the hub.

As a variation, reference may be had to the smaller bevel gear at the right in Fig. 15, which is represented as made up of nesting conical shaped laminae 57 mounted on the hub of a stud 58 and secured to the head 59 thereof by-suitable rivets 60.

The laminae of the stepped beveled gears may be formed of sheet metal or may be formed alternately of sheetmetal and fibrous or other non-metallic material, either punched or molded in the manner reviously referred to for spur gears and it will be understood that by properly proportioning the dies, gears of various SIZBS may be produced in the manner described.

It will be obvious that various modifications in the method of forming the lamina and in specific details of construction may be made without departing and scope of the invention.

1. The method of forming laminated stepped bevel gears which coinprises punching the successive gear laminae with aligning holes therein, forming the successive gear laminae to nest so that the teeth thereof are disposed at the proper bevel angle with respect to the axis of the gear, the aligning holes in successive gear lamina being advanced a predetermined amount with respect to the gear teeth, whereby when the gear laminae are assembled, the teeth of successive laminae are advanced uniformly to produce a stepped bevel gear.

2. The method of forming a laminated stepped bevel gear the alternate laminae of which are of metallic and non-metallic material, which comprises forming successive laminae, cup-shaped, with properly beveled gear teeth, the laminae nesting one within from the spirit the other, then securing the laminae together half of the gear teeth as the third step, an

means for changing the position of the punches and dies for punching the aligning holes relative to the position of the gear teeth.

4. In a three-step punch and die, for

. punching gear laminae, from sheet material, the combination of punches and dies for progressively forming the aligning holes and gear teeth, and means for changing the position of the aligning hole punches and dies, whereby the relative position of the aligning holes may be uniformly and progressively varied with respect to the teeth of the gears punched.

5. A multiple-step punch and die for punching gear laminae comprising punches and dies for forming the gear teeth, punches and dies for punching aligning holes, and means for changing the relation between said punches and dies, whereby the aligning holes for successive assembled laminae are progressively advanced with respect to the gear teeth.

JOSEPH F. KELLER. 

